Synchronous expansion shaping tool for single-turn frame type flat copper pole phase assembly coil

Abstract

The utility model discloses a synchronous expanding and shaping tool for a single-turn frame type flat copper pole-phase assembly coil, which realizes one-time forming when the pole-phase assembly coil is manufactured, firstly, a single-turn flat copper continuously-wound fusiform coil is obtained by winding in a multi-strand parallel winding mode, and then, the single-turn frame type flat copper continuously-wound fusiform coil is formed by winding in a multi-strand parallel winding mode. The single-turn flat copper continuously-wound fusiform coil is generally composed of six continuously-wound and serially-connected single-turn flat copper fusiform coils. A tool of a stator iron core where a pole-phase group coil is located is simulated and constructed after the pole-phase group coil is embedded into the stator iron core, and a single-turn flat copper continuous winding fusiform coil is formed into a single-turn frame type flat copper pole-phase group coil through the tool. The tool can synchronously perform expansion shaping on the single-turn flat copper fusiform coil to form a single-turn frame type flat copper pole phase group coil at one time; therefore, the consistency of the pole-phase assembly coil is ensured, the forming quality of the single-turn frame type flat copper pole-phase assembly coil is improved, and the investment cost of tool equipment is reduced.

Description

Technical Field

[0001] The present invention relates to a tool for expanding and shaping a generator stator coil, and in particular to a tool for synchronously expanding and shaping a single-turn flat copper shuttle coil into a single-turn frame-type flat copper pole phase group coil. Background Art

[0002] The stator coils of some marine generators are composed of single-turn frame-type flat copper pole phase group coils, which are distributed in the adjacent six slots of the same pole phase group of the motor stator. The pole phase group coils are composed of multiple single-turn (multi-strand parallel-wound) frame coils connected in series. The existing technology for preparing such coils and embedding them into the motor stator slots is as follows: first, a single-turn flat copper shuttle coil is made, and then the single-turn flat copper shuttle coil is placed on a coil expansion machine for expansion to obtain a single frame-type flat copper coil that can be directly embedded in the motor stator slot; after the multiple single frame-type flat copper coils are formed, each coil is embedded in the six slots corresponding to the pole phase group of the stator core respectively, and finally, the embedded six coils are welded in series in sequence to form the pole phase group coils of the same pole phase group; the above process results in a large number of welding points and wrapping points of the pole phase group coils, which greatly reduces the conductive reliability of the stator winding.

[0003] In order to improve the conductive reliability of the pole phase group coil winding, some motor manufacturers have begun to adopt the process of first making a single-turn frame flat copper pole phase group coil, and then embedding it as a whole into the adjacent 6 stator core slots of the same pole phase group of the stator core. The specific method of this process is: first make a single-turn flat copper shuttle coil with six turns, and then place the single-turn flat copper shuttle coil with six turns on the modified expansion machine for expansion of an approximate shape, so that it is initially formed into the shape of a single-turn frame flat copper pole phase group coil, and then place it on the shaping machine. The coil is precisely shaped on the mold to form a single-turn frame-type flat copper pole phase group coil that can be directly embedded with wires. Using this process, the existing expansion machine must first be modified to make it suitable for the expansion of multi-turn shuttle coils. There are defects in that the expansion machine is difficult to modify and the modified expansion machine can no longer expand a single coil. In addition, the coil must be shaped after expansion, and an additional shaping mold must be developed and manufactured. This method causes a significant increase in the manufacturing cost of tooling equipment, and the efficiency of forming the single-turn frame-type flat copper pole phase group coil is not improved. Summary of the Invention

[0004] The invention provides a synchronous expansion and shaping tool for a single-turn frame-type flat copper pole phase group coil, which realizes one-time forming when manufacturing the pole phase group coil and improves the forming quality of the coil.

[0005] The present invention solves the above technical problems through the following technical solutions:

[0006] The overall concept of the present invention is: firstly, a single-turn flat copper continuous-wound shuttle coil is obtained by winding multiple strands in parallel, and the single-turn flat copper continuous-wound shuttle coil is generally composed of six single-turn flat copper shuttle coils connected in series; then, a tooling of the stator core where the pole phase group coil is located is simulated and constructed when the pole phase group coil has been embedded in the stator core, and the single-turn flat copper continuous-wound shuttle coil is formed into a single-turn frame-type flat copper pole phase group coil by the tooling, so that the tooling can simultaneously expand and shape the single-turn flat copper shuttle coil into a single-turn frame-type flat copper pole phase group coil in one go; thereby, the consistency of the pole phase group coil is ensured, the forming quality of the single-turn frame-type flat copper pole phase group coil is improved, and the investment cost of tooling equipment is reduced.

[0007] A synchronous expansion and shaping tool for a single-turn frame-type flat copper pole phase group coil, comprising a working platform and a single-turn flat copper continuous winding shuttle coil, wherein the single-turn flat copper continuous winding shuttle coil is formed by winding multiple strands of parallel flat copper wire in a continuous winding manner, and is formed with an upper edge of the shuttle coil, a lower edge of the shuttle coil and a slanted side edge of the shuttle coil; a front arc-shaped bottom mold block of one-eighth cylinder for forming the upper edge of the pole phase group coil and a rear arc-shaped bottom mold block of three-eighth cylinder for forming the lower edge of the pole phase group coil are fixedly arranged on the working platform, the central axis of the circle where the top arc surface of the front arc-shaped bottom mold block is located coincides with the central axis of the circle where the top arc surface of the rear arc-shaped bottom mold block is located, and an arc-shaped step is provided between the top arc surface of the front arc-shaped bottom mold block and the top arc surface of the rear arc-shaped bottom mold block; a straight arc surface of the upper edge of the forming coil is provided in the middle of the top arc surface of the front arc-shaped bottom mold block, The top arc surface of the front arc-shaped bottom mold block on both sides of the upper straight arc surface of the forming coil is provided with an upper beveled conical arc surface of the forming coil, and upper side strips are fixedly arranged on the upper straight arc surface of the forming coil in parallel and at equal intervals, and an upper side embedding groove is formed between the two adjacent upper side strips, and an upper beveled guide positioning block is provided on the upper beveled conical arc surface of the upper side of the forming coil; the lower straight arc surface of the forming coil is provided in the middle of the top arc surface of the rear arc-shaped bottom mold block, and the lower beveled conical arc surface of the forming coil is provided on the top arc surface of the rear arc-shaped bottom mold block on both sides of the lower straight arc surface of the forming coil, and lower side strips are fixedly arranged on the lower straight arc surface of the forming coil in parallel and at equal intervals, and a lower side embedding groove is formed between the two adjacent lower side strips, and lower beveled guide positioning blocks are arranged at intervals on the lower beveled conical arc surface of the forming coil.

[0008] A support shaft of an expandable swing arm frame is fixedly arranged under the table of the working platform, and the support shaft of the expandable swing arm frame is arranged at the central axis position of the circle where the top arc surface of the front arc-shaped bottom mold block is located; a door-shaped expandable swing arm frame is movably connected to both ends of the support shaft of the expandable swing arm frame, and the lower end of the expandable swing arm frame is movably connected to the end of the support shaft of the expandable swing arm frame through a sleeve; a crossbeam is arranged on the expandable swing arm frame, and a pair of L-shaped clamps are arranged on the crossbeam.

[0009] The lower edges of the single-turn flat copper continuous shuttle coils are correspondingly embedded in the lower edge embedding grooves, and arc-shaped pressure strips are provided between the top surfaces of the lower edge strips; the upper edges of the shuttle coils are clamped in a pair of L-shaped clamps.

[0010] An upper top pressure strip is movably provided in the downwardly opening clamp of the L-shaped clamp, and the lower end of the top screw passes through the top surface of the L-shaped clamp and is connected to the top surface of the upper top pressure strip. A lower sealing block insertion groove is provided at the lower end of the downwardly opening clamp of the L-shaped clamp, and a lower sealing block is movably inserted in the lower sealing block insertion groove, and the upper edge of the shuttle coil is clamped between the upper top pressure strip and the lower sealing block.

[0011] A twist nose clip is provided in the middle of the oblique side of the shuttle coil, a U-shaped clip is provided on the twist nose clip, a snap pin is provided at the open end of the U-shaped clip, the middle of the oblique side of the shuttle coil is clamped between the opening of the U-shaped clip and the snap pin, and a handle is connected to the twist nose clip.

[0012] A one-time forming method for a single-turn frame type flat copper pole phase group coil is formed by a synchronous expansion and shaping tooling of the single-turn frame type flat copper pole phase group coil, characterized in that a front arc-shaped bottom mold block with a shape of one-eighth of a cylinder for forming the upper side of the pole phase group coil and a rear arc-shaped bottom mold block with a shape of three-eighths of a cylinder for forming the lower side of the pole phase group coil are fixedly arranged on the working platform of the synchronous expansion and shaping tooling, the central axis of the circle where the top arc surface of the front arc-shaped bottom mold block is located is aligned with the central axis of the circle where the top arc surface of the rear arc-shaped bottom mold block is located. The central axes of the upper edges of the forming coils coincide with each other; a straight arc surface is provided on the middle of the top arc surface of the front arc-shaped bottom mold block; upper beveled conical arc surfaces are provided on the top arc surfaces of the front arc-shaped bottom mold blocks on both sides of the upper straight arc surface of the forming coils; upper edge strips are fixedly provided parallel to each other and at equal intervals on the upper straight arc surfaces of the forming coils; an upper edge embedding groove is formed between adjacent two upper edge strips; upper beveled edges are provided at intervals on the beveled conical arc surfaces of the upper edges of the forming coils. Guide positioning block; a straight arc surface of the lower layer of the forming coil is provided in the middle of the top arc surface of the rear arc bottom mold block, and a beveled conical arc surface of the lower layer of the forming coil is provided on the top arc surface of the rear arc bottom mold block on both sides of the straight arc surface of the lower layer of the forming coil. On the straight arc surface of the lower layer of the forming coil, lower edge strips are fixedly provided parallel to each other and at equal intervals, and a lower edge embedding groove is formed between the two adjacent lower edge strips. Lower beveled guide positioning strips are provided at intervals on the beveled conical arc surface of the lower layer of the forming coil. Block; a support shaft of an expandable swing arm frame is fixedly provided under the table of the work platform, and the support shaft of the expandable swing arm frame is provided at the central axis position of the circle where the top arc surface of the front arc-shaped bottom mold block is located; a gate-shaped expandable swing arm frame is movably connected to both ends of the support shaft of the expandable swing arm frame, and the lower end of the expandable swing arm frame is movably sleeved on the end of the support shaft of the expandable swing arm frame through a sleeve; a crossbeam is provided on the expandable swing arm frame, and a pair of L-shaped clamps are provided on the crossbeam; the one-time forming method of the single-turn frame-type flat copper pole phase group coil comprises the following steps:

[0013] The first step is to make a single-turn flat copper continuous-wound shuttle coil by continuous winding of multiple strands of parallel-wound flat copper wire, wherein each coil has an upper side of the shuttle coil, a lower side of the shuttle coil, and a slanted side of the shuttle coil;

[0014] The second step is to embed the lower edges of each shuttle coil of the single-turn flat copper continuous shuttle coil into the lower edge embedding groove accordingly, and set an arc-shaped pressure strip between the top surfaces of each lower edge strip to press the lower edge of each shuttle coil tightly into the lower edge embedding groove;

[0015] Step 3: Swing the expansion arm frame backward to the top of the single-turn flat copper continuous winding shuttle coil, and then clamp the upper edge of the shuttle coil of the frontmost coil in the single-turn flat copper continuous winding shuttle coil in a pair of L-shaped clamps;

[0016] Step 4: Place a twist nose clip on the middle of the oblique side of the frontmost coil in the single-turn flat copper continuous shuttle coil to clamp the twist nose of the coil;

[0017] The fifth step is to swing the expansion swing arm frame forward and expand and shape the frontmost coil in the single-turn flat copper continuous shuttle coil so that the two oblique sides of the coil are formed under the guidance of the lower oblique side guide positioning block and the upper oblique side guide positioning block. In this process, the twisted nose of the coil is kept in a loose state by the twist nose clamp until the upper side of the shuttle coil is pulled to the top of the upper side embedded groove at the front end, and then, release a pair of L-shaped clamps, press the upper side of the shuttle coil down and embed it into the upper side embedded groove, take the upper side embedded rear pressure strip, and press the upper side embedded rear pressure strip into the upper side embedded groove above the upper side of the shuttle coil, and finally, take the upper side pressing block and fix it between the two adjacent upper side strips to form a fixed pressure on the upper side of the embedded shuttle coil; thereby completing the expansion and shaping of the frontmost coil in the single-turn flat copper continuous shuttle coil.

[0018] Step 6. Swing the expansion swing arm frame backward for the second time to the top of the single-turn flat copper continuous shuttle coil, and then clamp the upper edge of the shuttle coil of the second coil on the front side of the single-turn flat copper continuous shuttle coil in a pair of L-shaped clamps; repeat steps 4 to 5 to complete the expansion and shaping of the second coil on the front side of the single-turn flat copper continuous shuttle coil; repeat this cycle until the expansion and shaping of each coil of the single-turn flat copper continuous shuttle coil are completed.

[0019] After removing the upper edge pressure block, twist nose clip and arc-shaped pressure strip, taking out the upper edge and embedding the rear pressure strip, the formed single-turn frame-type flat copper pole phase group coil is taken out from the front arc-shaped bottom mold and the rear arc-shaped bottom mold. The lower edge of the shuttle-shaped coil forms the lower edge of the single-turn frame-type flat copper pole phase group coil. After the upper edge of the shuttle-shaped coil is pulled and expanded, the upper edge of the single-turn frame-type flat copper pole phase group coil is formed. The twist nose of the single-turn frame-type flat copper pole phase group coil is formed in the middle of the oblique side of the shuttle coil.

[0020] The present invention uses a single-turn flat copper continuous-wound shuttle coil as raw material, and integrates the two processes of expansion and shaping into the tooling. The operation is convenient and efficient. The formed single-turn frame-type flat copper pole phase group coil has good consistency, which speeds up the production and installation of the motor stator coil and reduces the investment cost of non-standard tooling. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 This is a structural diagram of the present invention when a single-turn flat copper continuous-wound shuttle coil is expanded and shaped;

[0022] Figure 2 This is a schematic structural diagram of the present invention when the expansion swing arm frame 3 is connected to the upper edge 28 of the shuttle coil;

[0023] Figure 3 This is a schematic structural diagram of a single-turn flat copper continuous-wound shuttle coil of the present invention;

[0024] Figure 4 It is a structural schematic diagram of the working platform 1 of the present invention;

[0025] Figure 5 It is a schematic diagram of the tooling structure of the present invention;

[0026] Figure 6 Schematic diagram of the top curved surface of the front curved bottom mold block 11 and the top curved surface of the rear curved bottom mold block 12 of the present invention;

[0027] Figure 7 This is a schematic structural diagram of the expandable swing arm frame 3 of the present invention;

[0028] Figure 8 It is a schematic structural diagram of the nose twist clip 29 of the present invention;

[0029] Figure 9 It is a structural schematic diagram of the formed single-turn frame-type flat copper pole phase group coil of the present invention. DETAILED DESCRIPTION

[0030] The present invention is described in detail below with reference to the accompanying drawings:

[0031] A synchronous expansion and shaping tool for a single-turn frame-type flat copper pole phase group coil, comprising a working platform 1 and a single-turn flat copper continuous winding shuttle coil, wherein the single-turn flat copper continuous winding shuttle coil is formed by winding a plurality of parallel flat copper wires in a continuous winding manner, and the group of coils is generally composed of 6-8 single-turn shuttle coils connected in series, and the group of coils is used as a raw material, and after expansion and shaping, a group of pole phase group coils is formed, and the formed group of pole phase group coils can be integrally embedded in the stator core of the motor to form coils of the same pole phase group; each shuttle coil in the single-turn flat copper continuous winding shuttle coil is provided with an upper edge 28 of the shuttle coil, a lower edge 26 of the shuttle coil and a bevel side edge 27 of the shuttle coil; in the working The platform 1 is fixedly provided with a front arc-shaped bottom mold block 11 of one-eighth cylinder for forming the upper edge of the pole phase group coil and a rear arc-shaped bottom mold block 12 of three-eighth cylinder for forming the lower edge of the pole phase group coil. The front arc-shaped bottom mold block 11 is a horizontally placed one-eighth cylinder. The arc surface of the one-eighth cylinder is designed to simulate the state of the electrode core embedded in the upper edge of the single-turn frame flat copper pole phase group coil. The arc surface of the one-eighth cylinder also becomes the supporting embedding mold for the upper edge 28 of the bulging shuttle coil. Similarly, the rear arc-shaped bottom mold block 12 is a horizontally placed three-eighth cylinder. The arc surface of the three-eighth cylinder It is designed to simulate the state of the electrode core embedded in the lower edge of the single-turn frame-type flat copper pole phase group coil. The arcuate surface of the three-eighths cylinder also becomes the supporting embedding mold for the lower edge 26 of the bulging shuttle coil. The front arc-shaped bottom mold block 11 and the rear arc-shaped bottom mold block 12 are fixed on the working platform 1 after docking to form an bulging shaping mold; the central axis of the circle where the top arcuate surface of the front arc-shaped bottom mold block 11 is located and the central axis of the circle where the top arcuate surface of the rear arc-shaped bottom mold block 12 is located coincide with each other, and an arc-shaped step is provided between the top arcuate surface of the front arc-shaped bottom mold block 11 and the top arcuate surface of the rear arc-shaped bottom mold block 12 to simulate a single turn. The forming support surfaces of the upper side, lower side and side bevel of the frame-type flat copper pole phase group coil; a straight arc surface 23 of the upper side of the forming coil is provided in the middle of the top arc surface of the front arc bottom mold block 11, and a tapered arc surface 24 of the upper side bevel of the forming coil is provided on the top arc surface of the front arc bottom mold block 11 on both sides of the upper side straight arc surface 23 of the forming coil. Upper side strips 17 are fixedly provided parallel to each other and at equal intervals on the upper side straight arc surface 23 of the forming coil, and an upper side embedding groove 18 is formed between two adjacent upper side strips 17. An upper bevel guide positioning block 19 is provided on the tapered arc surface 24 of the upper side bevel of the forming coil;A straight arc surface 21 of the lower side of the forming coil is provided in the middle of the top arc surface of the rear arc bottom mold block 12, and a beveled conical arc surface 22 of the lower side of the forming coil is provided on the top arc surface of the rear arc bottom mold block 12 on both sides of the straight arc surface 21 of the lower side of the forming coil. Lower side strips 13 are fixedly provided on the straight arc surface 22 of the lower side of the forming coil in parallel with each other and at equal intervals, and a lower side embedding groove 14 is formed between two adjacent lower side strips 13. Lower beveled guide positioning blocks 16 are provided at intervals on the beveled conical arc surface 22 of the lower side of the forming coil; the lower side embedding groove 14 is a single-turn flat copper continuous winding. The lower edge of the shuttle coil provides a positioning and support groove. By pulling the upper edge 28 of the shuttle coil, the single-turn flat copper continuous-wound shuttle coil is expanded and shaped into a single-turn frame-type flat copper pole-phase assembly coil. The upper edge then engages the groove 18, providing a positioning, forming, and fixing groove for the upper edge 33 of the expanded single-turn frame-type flat copper pole-phase assembly coil. During the entire expansion process, the curved top surface of the mold and the guide positioning block simultaneously expand and shape the oblique side edge 27 of the shuttle coil into the oblique side edge of the single-turn frame-type flat copper pole-phase assembly coil. A single tool simultaneously achieves expansion and shaping, allowing the single-turn flat copper continuous-wound shuttle coil to be formed into a single-turn frame-type flat copper pole-phase assembly coil in one go.

[0032] A support shaft 2 of an expanding swing arm frame is fixedly arranged under the table of the working platform 1, and the support shaft 2 of the expanding swing arm frame is arranged at the central axis position of the circle where the top arc surface of the front arc-shaped bottom mold block 11 is located; a door-shaped expanding swing arm frame 3 is movably connected to both ends of the support shaft 2 of the expanding swing arm frame, and the lower end of the expanding swing arm frame 3 is movably sleeved on the end of the support shaft 2 of the expanding swing arm frame through a sleeve 4; a crossbeam 5 is arranged on the expanding swing arm frame 3, and a pair of L-shaped clamps 6 are arranged on the crossbeam 5; the expanding swing arm frame 3 can be operated to swing to realize the expansion of the single-turn flat copper continuous winding shuttle coil.

[0033] The lower edges 26 of each shuttle coil of the single-turn flat copper continuous shuttle coil are correspondingly embedded in the lower edge embedding groove 14, and an arc-shaped pressure strip 15 is arranged between the top surfaces of each lower edge strip 13. The arc-shaped pressure strip 15 positions, fixes and presses the lower edges of each single-turn flat copper continuous shuttle coil embedded in the corresponding lower edge embedding groove 14; the upper edges 28 of the shuttle coil are clamped in a pair of L-shaped clamps 6, and the expanding swing arm frame 3 realizes the pulling and expanding of the upper edges of the single-turn flat copper continuous shuttle coil through a pair of L-shaped clamps 6.

[0034] An upper top pressure strip 8 is movably provided in the downwardly opening clamp of the L-shaped clamp 6, and the lower end of the top screw 7 passes through the top surface of the L-shaped clamp 6 and is connected to the top surface of the upper top pressure strip 8. A lower sealing block insertion groove 9 is provided at the lower end of the downwardly opening clamp of the L-shaped clamp 6, and a lower sealing block 10 is movably inserted in the lower sealing block insertion groove 9. The upper edge 28 of the shuttle coil is clamped between the upper top pressure strip 8 and the lower sealing block 10.

[0035] A twist nose clip 29 is provided in the middle of the oblique side 27 of the shuttle coil, a U-shaped clip 30 is provided on the twist nose clip 29, and a snap pin 31 is provided at the open end of the U-shaped clip 30. The middle of the oblique side of the shuttle coil is clamped between the opening of the U-shaped clip 30 and the snap pin 31, and a handle 32 is connected to the twist nose clip 29; since the oblique side 27 of the shuttle coil is also composed of multiple strands of flat copper wire wound in parallel, the multiple strands of flat copper wire are fixed by the twist nose clip 29 and, at the same time, are shaped into a twist nose shape.

[0036] A one-time forming method for a single-turn frame-type flat copper pole phase group coil is formed by a synchronous expansion and shaping tooling of the single-turn frame-type flat copper pole phase group coil. A front arc-shaped bottom mold block 11 with a shape of one-eighth of a cylinder for forming the upper side of the pole phase group coil and a rear arc-shaped bottom mold block 12 with a shape of three-eighths of a cylinder for forming the lower side of the pole phase group coil are fixedly arranged on a working platform 1 of the synchronous expansion and shaping tooling. The central axis of the circle where the top arc surface of the front arc-shaped bottom mold block 11 is located coincides with the central axis of the circle where the top arc surface of the rear arc-shaped bottom mold block 12 is located. A straight arc surface 23 of the upper side of the forming coil is provided in the middle of the top arc surface of the upper arc bottom mold block 11. On the top arc surfaces of the front arc bottom mold block 11 on both sides of the straight arc surface 23 of the upper side of the forming coil, there are provided beveled conical arc surfaces 24 of the upper side of the forming coil. Upper side strips 17 are fixedly provided parallel to each other and at equal intervals on the straight arc surface 23 of the upper side of the forming coil. An upper side embedding groove 18 is formed between two adjacent upper side strips 17. Upper beveled guide positioning blocks 19 are provided at intervals on the beveled conical arc surface 24 of the upper side of the forming coil. A straight arc surface 21 of the lower side of the forming coil is provided in the middle of the top arc surface of the rear arc bottom mold block 12. A beveled conical arc surface 22 of the lower side of the forming coil is provided on the top arc surface of the rear arc bottom mold block 12 on both sides of the straight arc surface 21 of the lower side of the forming coil. On the straight arc surface 22 of the lower side of the forming coil, lower side strips 13 are fixedly provided in parallel and at equal intervals. A lower side embedding groove 14 is formed between two adjacent lower side strips 13. Lower beveled guide positioning blocks are provided at intervals on the beveled conical arc surface 22 of the lower side of the forming coil. 16; A support shaft 2 of an expandable swing arm frame is fixedly provided below the tabletop of the work platform 1, and the expandable swing arm frame support shaft 2 is provided at the central axis position of the circle on which the top arc surface of the front arc-shaped bottom mold block 11 is located; a gate-shaped expandable swing arm frame 3 is movably connected to both ends of the expandable swing arm frame support shaft 2, and the lower end of the expandable swing arm frame 3 is movably sleeved on the end of the expandable swing arm frame support shaft 2 through a sleeve 4; a crossbeam 5 is provided on the expandable swing arm frame 3, and a pair of L-shaped clamps 6 are provided on the crossbeam 5; the one-time molding method of the single-turn frame-type flat copper pole phase group coil comprises the following steps:

[0037] In the first step, a single-turn flat copper continuous-wound shuttle coil is made by continuous winding multiple strands of parallel-wound flat copper wire. Each coil has a shuttle coil upper edge 28, a shuttle coil lower edge 26, and a shuttle coil oblique side edge 27.

[0038] In the second step, the lower edges 26 of the single-turn flat copper continuous shuttle coils are correspondingly embedded in the lower edge embedding grooves 14, and arc-shaped pressing strips 15 are provided between the top surfaces of the lower edge strips 13 to press the lower edges 26 of the shuttle coils tightly into the lower edge embedding grooves 14;

[0039] Step 3: Swing the expansion arm frame 3 backward to the top of the single-turn flat copper continuous winding shuttle coil, and then clamp the upper edge 28 of the shuttle coil of the frontmost coil in the single-turn flat copper continuous winding shuttle coil in a pair of L-shaped clamps 6;

[0040] Step 4: Install a nose clip 29 at the middle of the oblique side 27 of the frontmost coil in the single-turn flat copper continuous shuttle coil to clamp the nose of the coil.

[0041] The fifth step is to swing the expansion swing arm frame 3 forward and expand and shape the frontmost coil in the single-turn flat copper continuous shuttle coil so that the two oblique sides of the coil are formed under the guidance of the lower oblique side guide positioning block 16 and the upper oblique side guide positioning block 19. In this process, the twist nose of the coil is kept in a loose state by the twist nose clamp 29 until the upper side 28 of the shuttle coil is pulled to the front end and embedded above the upper side groove 18. Then, release the pair of L-shaped clamps 6 and The upper side 28 of the shuttle coil is pressed down and embedded into the upper side embedding groove 18, and the upper side embedding rear pressure strip 25 is taken out and pressed into the upper side embedding groove 18 above the upper side 28 of the shuttle coil. Finally, the upper side pressing block 20 is taken out and fixedly connected between the two adjacent upper side strips 17 to form a fixed pressure on the embedded upper side 28 of the shuttle coil; thereby completing the expansion and shaping of the frontmost coil in the single-turn flat copper continuous winding shuttle coil.

[0042] Step 6: Swing the expansion swing arm frame 3 backward for the second time to the top of the single-turn flat copper continuous shuttle coil, and then clamp the upper edge 28 of the shuttle coil of the second coil on the front side of the single-turn flat copper continuous shuttle coil in a pair of L-shaped clamps 6; repeat the steps from step 4 to step 5 to complete the expansion and shaping of the second coil on the front side of the single-turn flat copper continuous shuttle coil; and repeat this cycle until the expansion and shaping of each coil of the single-turn flat copper continuous shuttle coil are completed.

[0043] After removing the upper edge pressure block 20, the twist nose clip 29 and the arc-shaped pressure strip 15, and taking out the upper edge embedded in the rear pressure strip 25, the formed single-turn frame-type flat copper pole phase group coil is taken out from the front arc-shaped bottom mold 11 and the rear arc-shaped bottom mold 12, and the lower edge 26 of the shuttle-shaped coil forms the lower edge of the single-turn frame-type flat copper pole phase group coil. After the upper edge 28 of the shuttle-shaped coil is pulled and expanded, the upper edge 33 of the single-turn frame-type flat copper pole phase group coil is formed, and the twist nose of the single-turn frame-type flat copper pole phase group coil is formed in the middle of the oblique side 27 of the shuttle coil.

Claims

1. A synchronous expansion and shaping tool for a single-turn frame-type flat copper pole phase group coil, comprising a working platform (1) and a single-turn flat copper continuous winding shuttle coil, wherein the single-turn flat copper continuous winding shuttle coil is formed by winding a plurality of parallel flat copper wires in a continuous winding manner, and is formed with an upper edge (28) of the shuttle coil, a lower edge (26) of the shuttle coil and a slanted side edge (27) of the shuttle coil, and is characterized in that: A front arc bottom mold block (11) of one-eighth cylindrical shape for forming the upper edge of the pole phase group coil and a rear arc bottom mold block (12) of three-eighth cylindrical shape for forming the lower edge of the pole phase group coil are fixedly arranged on the working platform (1). The center axis of the circle where the top arc surface of the front arc bottom mold block (11) is located and the center axis of the circle where the top arc surface of the rear arc bottom mold block (12) is located are coincident with each other, and the front arc bottom mold block (1 1) is provided with an arc-shaped step between the top arc surface of the front arc-shaped bottom mold block (12); a straight-side arc surface (23) is provided on the middle of the top arc surface of the front arc-shaped bottom mold block (11); and an upper layer of the forming coil is provided with an oblique-side conical arc surface (24) on both sides of the upper layer of the forming coil. (23) are fixedly provided with upper side strips (17) parallel to each other and at equal intervals, and an upper side embedding groove (18) is formed between two adjacent upper side strips (17). An upper side bevel guide positioning block (19) is provided on the upper side bevel tapered arc surface (24) of the forming coil; a lower side straight arc surface (21) of the forming coil is provided in the middle of the top arc surface of the rear arc bottom mold block (12). The top arc surfaces of the rear arc bottom mold blocks (12) on both sides are provided with beveled conical arc surfaces (22) of the lower layer side of the forming coil, lower side strips (13) are fixedly provided on the straight arc surface (22) of the lower layer side of the forming coil in parallel and at equal intervals, a lower side embedding groove (14) is formed between two adjacent lower side strips (13), and lower beveled guide positioning blocks (16) are provided at intervals on the beveled conical arc surface (22) of the lower layer side of the forming coil.

2. The synchronous expansion and shaping tooling for a single-turn frame-type flat copper pole phase group coil according to claim 1 is characterized in that: A support shaft (2) of an expandable swing arm frame is fixedly arranged below the table of the working platform (1), and the support shaft (2) of the expandable swing arm frame is arranged at the central axis position of the circle where the top arc surface of the front arc-shaped bottom mold block (11) is located; a door-shaped expandable swing arm frame (3) is movably connected to both ends of the support shaft (2), and the lower end of the expandable swing arm frame (3) is movably sleeved on the end of the support shaft (2) of the expandable swing arm frame through a sleeve (4); a crossbeam (5) is arranged on the expandable swing arm frame (3), and a pair of L-shaped clamps (6) are arranged on the crossbeam (5).

3. The synchronous expansion and shaping tooling for a single-turn frame-type flat copper pole phase group coil according to claim 2 is characterized in that: The lower edges (26) of each shuttle coil of the single-turn flat copper continuous shuttle coil are correspondingly embedded in the lower edge embedding groove (14), and an arc-shaped pressure strip (15) is provided between the top surfaces of each lower edge strip (13); the upper edge (28) of the shuttle coil is clamped in a pair of L-shaped clamps (6).

4. The synchronous expansion and shaping tooling for a single-turn frame-type flat copper pole phase group coil according to claim 3 is characterized in that: An upper top pressure strip (8) is movably provided in the downwardly opening clamp of the L-shaped clamp (6), and the lower end of the top wire (7) passes through the top surface of the L-shaped clamp (6) and is connected to the top surface of the upper top pressure strip (8). A lower sealing block insertion groove (9) is provided at the lower end of the downwardly opening clamp of the L-shaped clamp (6), and a lower sealing block (10) is movably inserted into the lower sealing block insertion groove (9). The upper edge (28) of the shuttle coil is clamped between the upper top pressure strip (8) and the lower sealing block (10).

5. A synchronous expansion and shaping tool for a single-turn frame-type flat copper pole phase group coil according to claim 3 or 4, characterized in that: A twisting nose clip (29) is provided in the middle of the oblique side of the shuttle coil (27), a U-shaped clip (30) is provided on the twisting nose clip (29), a clamping pin (31) is provided at the open end of the U-shaped clip (30), the middle of the oblique side of the shuttle coil is clamped between the opening of the U-shaped clip (30) and the clamping pin (31), and a handle (32) is connected to the twisting nose clip (29).

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